Lightweight casket

ABSTRACT

A lightweight structurally sound casket formed preferably of a sandwich construction using a core of an open cell or honeycomb patterned material and fluid resistant surface elements. The casket is comprised of a body containment portion and a lid portion, each of which has the sandwich construction as the main structural element. The open cell material is structurally enhanced by being sandwiched between first and second stabilizing surface elements in both the body containment portion and the lid portion. In addition to the stabilizing surface elements, an aesthetically pleasing material is adhered to the outer portions of the body containment section and lid so that the casket has an attractive appearance. The body containment portion is constructed from rectangular pieces of the open cell material and stabilizing surface elements by folding the same into a box-like configuration. The lid portion is formed from placing the open cell material and the stabilizing surface elements into a jig, applying adhesive between the elements and finally, applying pressure thereto for adhering the elements together. As a final touch to the casket, ornamental features such as corner pieces and handles are added to the casket for aesthetic effects. The casket is environmentally safe for cremation and interment ceremonies and is economic and lightweight.

BACKGROUND OF THE INVENTION

[0001] This invention relates to caskets or coffins used to house theremains of once living organisms. More particularly, this invention isdirected toward a lightweight yet structurally strong casket highlysuitable for cremation-type and interment ceremonies. The casketexhibits excellent structural integrity while being highly flammable andminimally harmful to the environment.

[0002] The riddance of the bodies of the deceased can be accomplished inseveral ways, including burial and cremation. Because of the growingconcern for the world's environment, both of these methods have beenhighly scrutinized. Environmental problems include the overpopulation ofcemeteries and the effects of placing a corpse into the ground. Inaddition, environmental concerns arise from cremation, which is done inpart to alleviate the concerns regarding burial, wherein harmfulvolatile organic compounds (VOC's) are released to the atmosphere viathe burning of environmentally unsafe materials which are often used tomanufacture caskets or coffins.

[0003] In response to the environmental concerns surrounding cremationand in response also to the ever-rising costs of coffins and/or casketsfor burial, inexpensive, lightweight and environmentally safe casketshave been developed. Most of these caskets are constructed fromcorrugated cardboard or the like. Corrugated cardboard tends to absorbmoisture and degrades structurally when it is exposed thereto. However,because of the inadequate structural integrity of corrugated cardboardcaskets, such caskets tend to twist and bend thereby threatening thesecurity of the corpse therein and risking the stability of the mentalhealth of friends and relatives who may unwantingly witness anunscheduled viewing of the deceased should the casket fail.

[0004] In the prior art, for example, the patent to Elder, U.S. Pat. No.4,967,455 discloses a cardboard casket and a method of manufacturing thesame. The patent discloses a corrugated cardboard casket constructedfrom multiple blanks of cardboard which are attached and folded tocreate the enclosure which forms the casket. However, as can be seenfrom the drawing and the text, only the use of corrugated cardboard isdisclosed. Corrugated cardboard, which is currently and predominantlyused in making lightweight caskets, inherently lacks structuralintegrity and, therefore, causes things made from it to also lackstructural integrity. Therefore, the casket in Elder poses the risk ofstructural failure.

[0005] For the morbid partygoer, U.S. Pat. No. 4,891,869 to Nutting,discloses a cardboard coffin for use at parties or similar occasionswhich is formed from a plurality of corrugated cardboard blanks. Again,the coffin is constructed by folding the corrugated cardboard into theshape of the casket or coffin. As with Elder, the use of the corrugatedcardboard fails to provide the coffin with the necessary strength andstructural rigidity of a more expensive coffin constructed from strongermaterials.

[0006] While the foregoing patents disclose the use of cardboard forconstructing a more economical and environmentally safe casket, none ofthe prior patents discloses the use of polymer coated cellulose fiber(PCCF) or other material arranged in an open cell pattern or otherpatterns exhibiting similar high strength when constructed in accordancewith this invention.

SUMMARY OF THE INVENTION

[0007] The invention disclosed herein is directed toward an economicaland environmentally safe casket having excellent structural integrityfor maintaining the shape of the casket and for exhibiting low torsionaldisplacement during the carrying of the deceased. These properties areexhibited even when the casket is exposed to a high moistureenvironment.

[0008] In accordance with the invention, the lightweight casketcomprises a body containment compartment and a lid constructed from acore section of polymer coated cellulose fiber (PCCF) arranged in anopen cell pattern. The core section for both the lid and for the bodycontainment portion is comprised of a first and a second surface,wherein each surface is attached to a stabilizing surface elementthereby causing a sandwich-type effect. Additionally, the core of thissandwich could be made of a solid surface structural material such aspolystyrene foam.

[0009] The core section may be comprised of a plurality of honeycombcells wherein each cell is substantially a cylindrically shaped tube.The stabilizing surface elements are surface-treated planar sheets gluedor otherwise attached to the open cell patterned core of PCCF. Thecombination of the open cell pattern core and the sandwiching effect viathe stabilizing surface elements, supplies the structural rigidity ofthe casket. The core material provides the shear force for carrying thesandwich construction while the stabilizing surface elements carry thebending forces of the sandwich. The core material having the open cellsperpendicular to the stabilizing surface elements exhibit a muchstronger and stiffer structural shear carrying member than alongitudinally aligned corrugated configuration.

[0010] This invention also includes the method of constructing thelightweight casket. The open cell patterned core section is first cutinto a rectangular pattern suitable in size for folding into the bodycontainment section. A first stabilizing surface element is attached tothe underside of the core section, and a second stabilizing surfaceelement comprising a plurality of sections is similarly attached to theupper portion of the core section but arranged in a pattern allowing thefolding of the core section into the body containment section. Duringbonding of the stabilizing surface elements thereto, the core acts as apressure transfer mechanism to assure proper bonding. Upon folding, thewalls and bottom of the body containment section are established and areadhered to each other for maintaining the enclosure-type structure.Finally, a lid is formed in a similar manner from a core section andstabilizing surface elements which are caused to form a dome-like shapevia use of a jig and the application of air pressure.

[0011] The casket disclosed is lightweight yet structurally rigid forsupporting and carrying the contents placed therein. By using PCCF inlieu of more expensive materials, economic and environmental concernsare precluded while a very strong lightweight structure is establishedvia the use of the open cell pattern and stabilizing surface elements.

BRIEF DESCRIPTION OF THE DRAWINGS

[0012] For the purpose of illustrating the invention, there is shown inthe accompanying drawings one form which is presently preferred; itbeing understood that the invention is not intended to be limited to theprecise arrangements and instrumentalities shown.

[0013]FIG. 1 is a perspective view of a lightweight casket constructedin accordance with the principles of the present invention;

[0014]FIG. 2 is a partial cross sectional view taken along line 2 ofFIG. 1;

[0015]FIG. 3a discloses the use of a polystyrene based, solid surface,core in lieu of the honeycomb, open cell structure, core;

[0016]FIG. 3 is a perspective view of the honeycomb core and firststabilizing surface element;

[0017]FIG. 4 is a perspective view of the honeycomb core attached to thefirst and second stabilizing surface elements;

[0018]FIG. 5 is a view similar to FIG. 4 with the addition of a secondlayer of core section attached to the inner bottom surface of thecasket;

[0019]FIG. 6 Is a perspective view of the lightweight casket during thefolding stage;

[0020]FIG. 7 is a perspective exploded view of the casket showing theinsertion of the end inserts;

[0021]FIG. 8 is a perspective view of the body containment portion ofthe casket prior to the addition of aesthetic features;

[0022]FIG. 9 is a cross sectional view taken along line 9-9 of FIG. 8;

[0023]FIG. 10 is an exploded view of the method of construction of thecasket lid using a jig;

[0024]FIG. 11 is a perspective view of the casket lid and jig with thejig cover in the open position;

[0025]FIG. 12 is a perspective view of the jig cover and air pressureconnector, and

[0026]FIG. 13 is a cross-sectional view taken along line 13-13 of FIG.12.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0027] Referring now to the drawings in detail wherein like referencenumerals have been used throughout the various figures to designate likeelements, there is shown in FIG. 1 a perspective view of the lightweightcasket constructed in accordance with the principles of the presentinvention and designated generally as 10. The casket 10 is comprisedessentially of the body containment portion 12 and the lid section 14.As shown in FIG. 2 for the body containment portion, it is comprisedlargely of the open cell core section 16, preferably a honeycombpattern, being sandwiched between a first stabilizing surface element 18and a second stabilizing surface element 20, both of which are formedfrom a fluid resistant material. The lid 14 is constructed in asimilarly layered manner.

[0028] The formation of the body containment portion 12 is accomplishedin part as shown in FIG. 3. The honeycomb core 16 is cut to asubstantially rectangular shape and of a size adapted to be folded intothe casket. In forming the body containment portion 12, the firststabilizing surface element 18 is placed underneath the honeycomb core16, while the second stabilizing surface element 20 is placed on top ofthe honeycomb core 16, as shown in FIG. 4. The first stabilizing surfaceelement 18 is substantially rectangular in shape and scored with foldlines, as shown in FIG. 3, as well as being cut in four places 24 athrough 24 d. The first stabilizing surface element 18, as shown, islarger in length than the core section 16. The fold lines and the cuts24 a through 24 d function to facilitate the folding of the honeycombcore with the stabilizing surface elements attached thereto into theenclosure as shown in FIGS. 6, 7 and 8. The fold lines are not shown butare merely continuations of the cuts 24 a through 24 d as well as beingperpendicular to those cuts adjacent the edge of the core section 16.

[0029] The honeycomb core 16 is preferably formed from polymer coatedcellulose fiber (PCCF) sheets but environmentally safe plastic or thelike will also suffice. Tile core is comprised of a plurality oflongitudinally extending cylindrically shaped cells interconnected andforming a honeycomb pattern. Because of their cylindrical shape, themembers have strong structural rigidity along their longitudinal axes.

[0030] With the first stabilizing surface element 18 being scored andcut for folding, the honeycomb core 16 is adhered to the upper surfacethereof utilizing any suitable adhesive. In addition, an aestheticallypleasing material 26 is adhered to the underside of the firststabilizing surface element 18 for incorporating a pleasing texture andappearance to the casket. The second stabilizing surface element 20 issimilarly adhered to the honeycomb core. However, the stabilizingsurface element 20 is comprised of a plurality of separate sections 28 athrough 28 c. The sections 28 a through 28 c comprise threerectangularly-shaped planer sheets which are arranged upon the honeycombcore as shown in FIG. 4. As can be seen, the separate sections are ofsizes which allow spaces between the sections leaving rectangularportions 30 a and 30 b of exposed honeycomb.

[0031] In a second embodiment, these spaces of core material leftbetween the stabilizing elements may be cut on a forty five degree anglefrom the stabilizing element edges to the middle of the space. Theseangled cuts help to facilitate the folding of the core material andstabilizing elements into the body containment section. In a thirdembodiment, the core material between the stabilizing elements isremoved and inserts are placed in the spaces for additional support.

[0032] The purpose of the sandwiching effect of the honeycomb corebetween the two stabilizing sections is to provide the honeycomb corewith structural rigidity by maintaining the cells of the core in asubstantially perpendicular orientation to applied forces. The core actsas a pressure transfer mechanism and transfers the load to the outerstabilizing surface element 18 when a force is applied thereto. Byleaving uncovered the exposed honeycomb core sections 30 a and 30 b, asprovided for by the separate sections, the exposed honeycomb lacks thestructural rigidity of the sandwiched honeycomb core. These exposed and,therefore, weaker sections of honeycomb inherently create fold lines onthe core surface.

[0033] In addition to the core 16, an additional layer 32 of core, asshown in FIG. 5, is glued to the structure over the center portion 28 bof the second stabilizing surface element 20. The additional core 32 isof substantially the same size as the center portion 28 b and inaddition has a third stabilizing surface element 34 glued to the topthereof. The additional honeycomb core and stabilizing surface furtherstrengthens and increases the structural rigidity of the casket bottomand provides extra structural security.

[0034] Referring now to FIGS. 5 and 6, the lightweight casket is nowready for formation into the body containment portion 12. To initiatethis process, the sides of the casket 36 a and 36 b are folded upwardalong the fold lines (not shown), cut lines 24 a through 24 d and therectangular and exposed honeycomb sections 30 a and 30 b. By followingthis procedure, the formation shown in FIG. 6 is the result. Uponfolding the sides 36 a and 36 b, the corners 38 a through 38 d must befolded inward towards the center of the body containment portion 12. Asshown in FIG. 6, the corners 38 a through 38 d become part of the endsof the body container portion 12. However, the ends are furthercompleted by folding upward the end extensions 40 a and 40 b toward thefolded corners 38 a through 38 d. Before folding the extensions 40 a and40 b, adhesive is applied on the contact surfaces thereof for adherenceto the outside surfaces of the folded corners 38 a through 38 d. Thisprovides a double shear path and increases the strength of theenclosure.

[0035] Referring now to FIG. 7, the body containment portion is readyfor insert of the end inserts 42 a and 42 b. Each end insert iscomprised of the rectangular portion of honeycomb material having astabilizing surface element 44 adhered thereto. The stabilizing surfaceelements 44 a and 44 b are adhered to the surface of the end inserts 42a and 42 b facing the inner portion of the body containment portion 12wherein the end extensions 40 a and 40 b act as the other stabilizersfor the inserts 42 a and 42 b, respectively. Accordingly, the endinserts are inserted adjacent each end of the body containment portion.The side of each end insert having no stabilizing surface elementadhered thereto is placed adjacent and adhered to the inner surfaces ofthe folded corners 38 a through 38 d, the end insert 42 a being adheredto folded corners 38 a and 38 d, and end insert 42 b being adhered tofolded corners 38 b and 38 c. At this point in the construction process,the lightweight casket resembles the configuration shown in FIG. 8wherein the body containment portion 12 is fully constructed.

[0036] The lid of the lightweight casket is fabricated as shown in FIGS.10-13. Similar to the body containment portion, the lid 14 is formed byplacing a lid core section comprised of a honeycomb portion 46 betweentwo lid stabilizing surface elements 48 a and 48 b as shown in FIG. 10.Due to the curved shape of the lid, the construction of it requires asomewhat different process than the construction of the body containmentportion 12. The preferred method of constructing the lid 14 is toconstruct a jig 50 having an outer portion resembling the shape of thelid 14. The jig 50 is used to construct the lid 14 in a step-like mannerwhich includes the application of a pressure source 52.

[0037] As shown in FIG. 10, the jig 50 has an outer section 51 which issubstantially in the shape of the lid 14 shown in FIG. 1. To initiatethe lid construction process, the first stabilizing surface element 48 ais placed into the jig 50. As shown in FIG. 10, the first stabilizingsurface element is constructed from one to three separate elements, acenter element and two triangularly-shaped end elements. These elementsare placed into jig 50. Each of the elements has an edge 54 formed intoa rectangular shape and adapted to receive perimeter stabilizing bars 56a through 56 d. The perimeter stabilizing bars 56 a through 56 d formthe portion of the lid which contacts the body containment portion 12.It is important that the edges which contact the body containmentportion 12 have structural rigidity as well as the lid itself.Therefore, the perimeter bars 56 a through 56 d are placed into thefolded edges 54 a-54 d and secured therein by adhering the edges 54 a-54d thereto.

[0038] Referring still to FIG. 10, the honeycomb portion 46, similar tothat used with the body containment portion, is now placed into the jig50 and over the first stabilizing surface element 48 a. Prior to theinsert of the honeycomb 46, adhesive is spread over the firststabilizing surface element 48 a for causing the honeycomb portion 46 toadhere thereto. The honeycomb portion 46 is a substantially rectangularpiece of material which is cut to a size which conforms to the lid shapeand still contacts the entire surface of the entire first stabilizingsurface element, It is not necessary to cut or provide fold lines in thehoneycomb portion 46 in any manner due to the flexibility of the same inconforming to the general shape of the lid 14.

[0039] With the honeycomb portion 46 inserted therein, the secondstabilizing surface element 48 b is placed over the top of the insertedhoneycomb portion 46. The second stabilizing surface element 48 b isrectangular but is comprised of an odd shaped section 58 havingtriangularly shaped but integral end sections 59 a and 59 b and havingangular fold cuts as shown in FIG. 10. These sections 58 and 59 a and 59b are placed on the honeycomb portion 46 as shown in FIG. 11 and conformto the jig 50. Prior to placement onto the honeycomb portion 46,adhesive is applied to the side of the sections which will contact thehoneycomb portion 46. With all the elements in place, a pressure source52 is applied to the integrated sections.

[0040] As shown in FIGS. 11 and 12, a flexible cover 60 is hinged to andextends from the edges of the jig 50 via a hinged door 61 and is placedover the integrated elements just discussed, forming an air tight seal.The pressure source connector 62 extends from the flexible portion 60 soas to connect the pressure source 52 thereto. Accordingly, the pressuresource 52 is connected to the connector 62 and pressure is applied tothe lid 16. The pressure thereby forces the integrated sections togetherfor adhering those which are contacting each other and forcing them intothe shape of the jig 50. In addition, an aesthetically pleasing layer 64is applied to the lid 16 for matching the body containment portion 12.When the air is removed and the sections are adhered together, the jigis disassembled and the lid can be removed, resembling the configurationshown in FIG. 1.

[0041] The lid can also be formed in separate halves which is desirablefor viewing purposes. The formation of the lid into two separate halvesis performed essentially the same as just described except that eachhalf is constructed separately in the jig such that finished edges areformed all around.

[0042] For both the body containment portion 12 and the lid 14,materials and patterns other than PCCF arranged in a honeycomb patterncan be used. As shown in FIG. 3a, for example, an environmentally safepolystyrene-type material 65 can be used in lieu of the honeycombmaterial where it is placed between two stabilizing surface elements.Polystyrene foam placed between similar stabilizing surface elementsexhibits substantially the same structural rigidity as the honeycombportions and can be used interchangeably. Additionally, PCCF and othermaterials can be formed into truss patterns which also exhibit highstructural rigidity when sandwiched between the stabilizing surfaceelements.

[0043] Upon completion of the body containment portion 12 and the lid 14as substantially described, the lightweight casket is finished byattaching ornamental elements thereto which gives the casket a richerappearance. As shown in FIG. 1, preformed corner pieces 66 a through 66d are placed onto the corners of the lightweight casket 10. In additionto appearance, the corners 66 a-66 d provide extra strength in the bodycontainment portion 12. The corners 66 a through 66 d are comprisedsubstantially of two triangularly-shaped elements attachedperpendicularly to each other. The corners are covered with the sameaesthetically pleasing material as the rest of the lightweight casketexhibits. The corners 66 a through 66 d are simply glued to the bodycontainment compartment corners as shown in FIG. 1. In addition to thecorners, handles 68 are securely attached to each side of thelightweight casket for the carrying of the same. The inner portion ofthe lightweight casket in its finished condition is also designed in anaesthetically pleasing manner having linings and pillows.

[0044] The lightweight casket is used in a manner similar to any othercasket. Because of the structural rigidity providing by the sandwichingof either the open cell or solid surface core materials, there are nospecial precautions which must be considered in handling the lightweightcasket 10. The body is simply placed in the casket as with any othercasket and it can be carried similar to any other casket. For cremationpurposes, the casket is highly flammable and, as discussed, is notharmful to the environment and can simply be placed into the furnacewithout alteration.

[0045] The present invention may be embodied in other specific formswithout departing from the spirit or essential attributes thereof andaccordingly reference should be made to the appended claims rather thanto the foregoing specification as indicating the scope of the invention.

What is claimed is:
 1. A casket comprising a body containment sectiondefined by walls and a bottom being constructed from a core section,said core section comprising a first layer of material arranged in anopen cell pattern wherein said pattern is comprised of a plurality ofcells arranged substantially perpendicular to the bottom and walls. 2.The invention according to claim 1 wherein said core section has a firstand a second surface, said core section being further comprised of afirst stabilizing surface element attached to said first surface and asecond stabilizing surface element attached to said second surface, saidstabilizing surface elements and said first layer of material forming asandwich type structure.
 3. The invention according to claim 2 whereinsaid stabilizing surface elements are substantially fluid resistant. 4.The invention according to claim 2 wherein said casket has anaesthetically pleasing outer layer of material attached to said firststabilizing surface element and decorative corners and handles attachedto said outer layer.
 5. The invention according to claim 2 wherein saidbottom of said body containment section is comprised of a second layerof material arranged in an open cell pattern and a third stabilizingsurface element attached to said second layer of material, said secondlayer being attached to said first layer.
 6. The invention according toclaim 1 further comprising a lid formed from a lid core sectioncomprising said first layer of material arranged in an open cellpattern.
 7. The invention according to claim 6 wherein said lid coresection has a first and a second side, said lid core section furthercomprising a first lid stabilizing surface element attached to saidfirst side and a second lid stabilizing surface element attached to saidsecond side, said lid stabilizing surface elements and said first layerof material forming a sandwich type structure.
 8. The inventionaccording to claim 2 wherein said material is arranged in a honey combpattern and is lightweight and flammable.
 9. The invention according toclaim 8 wherein said material is comprised of polymer coated cellulosefibers in sheet form.
 10. A casket comprising a body containment sectiondefined by walls and a bottom being constructed from a core section,said core section comprising a flexible material attached to andsandwiched between at least two flexible surface members whereby saidcore section is a sandwich type structure being substantially inflexibleand exhibiting minimal torsional displacement upon application ofbending and torsional forces.
 11. The invention according to claim 10wherein said flexible material is a solid surface type material.
 12. Theinvention according to claim 11 wherein said material is polystyrenefoam.
 13. The invention according to claim 10 wherein said flexiblematerial is comprised of a material arranged in an open cell pattern,said pattern comprising a series of longitudinal cells wherein saidflexible surface members extend substantially perpendicularly to saidcells.
 14. The invention according to claim 13 wherein said material isarranged in a honeycomb pattern.
 15. The invention according to claim 14wherein said flexible material is polymer coated cellulose fiber. 16.The invention according to claim 14 wherein said flexible material isplastic.
 17. A method for constructing a casket comprising the steps of:providing a core section having a first and a second surface; providingfirst and second stabilizing surface elements; attaching said firststabilizing surface element to said first surface, and attaching saidsecond stabilizing surface element to said second surface, and shapingsaid core section and attached stabilizing surface elements into a bodycontainment section.
 18. The method of claim 17 further comprisingforming a lid from a lid core section comprised of material arranged inan open cell pattern.
 19. The method of claim 18 wherein said coresection is a material arranged in an open cell structure comprising aplurality of cells being positioned substantially perpendicular to saidstabilizing surface elements.
 20. The method of claim 18 furthercomprising the steps of: shaping said lid core section intosubstantially a cover-like configuration, said lid core section having atop and a bottom surface, and attaching lid stabilizing surface elementsto said top and bottom surfaces.
 21. The method in claim 20 furthercomprising the steps of: providing a jig adapted to receive pressure forshaping said lid core section and elements into said lid; placing saidlid stabilizing surface elements along with said lid core section andsaid outer layer into said jig; applying an adhesive between said lidcore section and said lid stabilizing surface elements; applying saidpressure thereto for evacuating air and for securing said lid coresection and outer layer to said lid stabilizing surface elements viasaid adhesive.
 22. The method according to claim 21 further comprisingthe step of adhering an aesthetically pleasing outer layer of materialto one of said lid stabilizing surface elements.
 23. The method of claim17 wherein said second element is comprised of a plurality of separatesections.
 24. The method of claim 23 further comprising the steps of:creating fold lines in said first stabilizing surface element prior toattachment of said core section for facilitating the formation of thecontainment section; attaching said plurality of separate elements tosaid core section and leaving spaces therebetween for facilitating thefolding of said core section; folding said core section and attachedstabilizing surface elements along said fold lines and spaces forforming the bottom and sides walls of said casket, and securing saidbottom and walls together for maintaining said core section and saidattached stabilizing surface elements in an enclosure-type arrangement.25. The method of claim 24 further comprising attaching an outer laterof material being of an aesthetically pleasing appearance.
 26. Themethod of claim 24 further comprising attaching an additional layer ofcore section to the bottom of said casket on the inside surface thereof.27. The method of claim 26 wherein said additional layer of core sectionis a material having a solid surface structure.
 28. The method of claim26 wherein said additional layer of core section is a material having anopen cell structure.